Compaction system for composite stringers

ABSTRACT

A method and apparatus for compacting composite stringers. In one illustrative embodiment, an apparatus comprises a compacting structure, a compactor vacuum system, and a carrier vacuum system. The compacting structure has a shape configured to contact layers of uncured composite material for a composite stringer. The compactor vacuum system is associated with the compacting structure. The compactor vacuum system is configured to cause the compacting structure to apply a pressure to the layers of uncured composite material when a compactor vacuum is applied to the compactor vacuum system. The carrier vacuum system is associated with the compacting structure. The carrier vacuum system is configured to hold the layers of uncured composite material against the compacting structure when a carrier vacuum is applied to the carrier vacuum system.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of and claims the benefit of priority toU.S. patent application Ser. No. 13/626,452, filed Sep. 25, 2012, theentire contents of which are incorporated herein by reference.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to aircraft and, in particular,to forming stringers in an aircraft. Still more particularly, thepresent disclosure relates to a method and apparatus for compactinglayers of uncured composite material for a composite stringer.

2. Background

Aircraft are being designed and manufactured with ever increasingpercentages of composite materials. Composite materials are used inaircraft to decrease the weight of the aircraft. This decreased weightimproves performance features such as payload capacity and fuelefficiency. Further, composite materials provide longer service life forvarious components in an aircraft.

Composite materials may be tough, light-weight materials created bycombining two or more functional components. For example, a compositematerial may include reinforcing fibers bound in a polymer resin matrix.The fibers may be unidirectional or may take the form of a woven clothor fabric. The fibers and resins may be arranged and cured to form acomposite structure.

Using composite materials to create aerospace composite structures mayallow for portions of an aircraft to be manufactured in larger pieces orsections. For example, a fuselage of an aircraft may be created incylindrical sections to form the fuselage of the aircraft. Otherexamples include, without limitation, wing sections joined together toform a wing or stabilizer sections joined together to form a stabilizer.

In manufacturing composite structures, layers of uncured compositematerial may be laid up on a tool. The layers of uncured compositematerial may be comprised of fibers in sheets. These sheets may take theform of, for example, without limitation, fabrics, tape, tows, or othersuitable configurations for the sheets. In some cases, resin may beinfused or pre-impregnated into the sheets. These types of sheets arecommonly referred to as prepreg.

The different layers of prepreg may be laid up in different orientationsand different numbers of layers of uncured composite material may beused depending on the desired thickness of the composite structure beingmanufactured. These layers of uncured composite material may be laid upby hand or by using automated lamination equipment such as a tapelaminating machine or a fiber placement system.

Laying up layers of uncured composite material to form differentstructures in an aircraft may be a complex and time-consuming task. Forexample, a section of a fuselage includes laying up layers of uncuredcomposite material for the walls of the fuselage.

Additionally, other features may be laid up or placed onto these layersfor curing at the same time. For example, stringers on the interiorwalls of the fuselage may be laid up along with the walls for thefuselage itself. For example, layers of uncured composite material inthe form of a stringer may be laid up on a tool. This tool may be aninner-mold line (IML) tool when the stringer is laid up with otherstructures to form a composite structure. In other illustrativeexamples, the tool may be used only for compacting the stringers. Theselayers may be compacted after being placed on the tool. A compactingdevice is used to hold the shape of the stringer and compact thestringers before curing the stringers with the other layers of uncuredcomposite material for the wall of the fuselage.

These compacting devices may take various forms. For example, a bladder,a mandrel, or some other suitable device may be placed against the innerwall of the stringer. After the stringers have been placed on the IMLtool, a vacuum bag may be placed over the stringers. A vacuum may thenbe applied to the vacuum bag to compact the layers of uncured compositematerial for the stringers. When a vacuum is applied, air and othergases in the vacuum bag are drawn out of the vacuum bag.

The stringers are often compacted in batches. In other words, stringersawaiting other stringers to be placed on the IML tool are not compacteduntil the additional stringers in another batch are ready. The stringersawaiting processing may change from the desired shape or shift formsbefore compactions occur for the batch of stringers.

Additionally, the process of installing the vacuum bag and applying thevacuum is a labor-intensive job performed by operators. The vacuum bagis placed over the stringers. The edges of the vacuum bag are sealed.Thereafter, a vacuum is drawn in the vacuum bag such that pressure isapplied on the compacting devices in the stringers.

The vacuum may be drawn for various periods of time. For example, thecompaction may require about thirty minutes. During this time, theoperators and other processes in forming the fuselage section are put onhold. After the stringers have been compacted, the vacuum bag is removedand the compaction devices are also removed from the stringers.Thereafter, any additional layers of uncured composite material may belaid up on the tool for curing. Thereafter, the fuselage section and thestringers may be cured to form the fuselage section.

This process is complex and time-consuming. The complexity and timeneeded to perform these operations may result in taking more time thandesired to form a composite fuselage section for an aircraft. Therefore,it would be desirable to have a method and apparatus that takes intoaccount at least some of the issues discussed above, as well as otherpossible issues.

SUMMARY

In one illustrative embodiment, an apparatus comprises a compactingstructure, a compactor vacuum system, and a carrier vacuum system. Thecompacting structure has a shape configured to contact layers of uncuredcomposite material for a composite stringer. The compactor vacuum systemis associated with the compacting structure. The compactor vacuum systemis configured to cause the compacting structure to apply a pressure tothe layers of uncured composite material when a compactor vacuum isapplied to the compactor vacuum system. The carrier vacuum system isalso associated with the compacting structure. The carrier vacuum systemis configured to hold the layers of uncured composite material againstthe compacting structure when a carrier vacuum is applied to the carriervacuum system.

In another illustrative embodiment, an apparatus comprises a compactingstructure and a compactor vacuum system. The compacting structure has ashape configured to contact an internal wall of layers of uncuredcomposite material for a composite stringer. The compactor vacuum systemis configured to cause the compacting structure to apply a pressure tothe layers of uncured composite material when a compactor vacuum isapplied to the compactor vacuum system.

In yet another illustrative embodiment, a method is present forprocessing a composite stringer. Layers of uncured composite materialfor a composite stringer are placed onto a tool. A compactor vacuum isapplied to a compactor vacuum system associated with a compactingstructure such that the layers of uncured composite material of thecomposite stringer are compacted against the tool.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a composite manufacturing environment inaccordance with an illustrative embodiment;

FIG. 2 is an illustration of a block diagram of a compositemanufacturing environment in accordance with an illustrative embodiment;

FIG. 3 is an illustration of a block diagram of a stringer processingdevice for processing a stringer in accordance with an illustrativeembodiment;

FIG. 4 is an illustration of a stringer processing device in accordancewith an illustrative embodiment;

FIG. 5 is an illustration of an isometric view of a stringer processingdevice in accordance with an illustrative embodiment;

FIG. 6 is an illustration of a stringer processing device with astringer preform positioned relative to a tool in accordance with anillustrative embodiment;

FIG. 7 is an illustration of a cross-sectional view of a stringerprocessing device holding a stringer preform in accordance with anillustrative embodiment;

FIG. 8 is another cross-sectional view of a stringer processing devicewith a stringer preform in a channel of a tool in accordance with anillustrative embodiment;

FIG. 9 is an illustration of a stringer processing device in accordancewith an illustrative embodiment;

FIG. 10 is an illustration of a cross-section of a stringer processingdevice in accordance with an illustrative embodiment;

FIG. 11 is another illustration of a cross section of a stringerprocessing device in accordance with an illustrative embodiment;

FIG. 12 is another illustration of a cross section of a stringerprocessing device in accordance with an illustrative embodiment;

FIG. 13 is yet another illustration of a cross section of a stringerprocessing device in accordance with an illustrative embodiment;

FIG. 14 is another illustration of a stringer processing device inaccordance with an illustrative embodiment;

FIG. 15 is an illustration of a flowchart of a process for processing acomposite stringer in accordance with an illustrative embodiment;

FIG. 16 is an illustration of a flowchart of a process for processingcomposite stringers in accordance with an illustrative embodiment;

FIG. 17 is an illustration of an aircraft manufacturing and servicemethod in accordance with an illustrative embodiment; and

FIG. 18 is an illustration of an aircraft in which an illustrativeembodiment may be implemented.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or moredifferent considerations. For example, the illustrative embodimentsrecognize and take into account that currently, the process ofcompacting stringers on a mold is not performed until a plurality orpossibly all of the stringers have been put in place. In some cases,some portion of the stringers may be put in place before the compactingoccurs. The time needed to place the stringers while concurrentlyinstalling the vacuum bag to compact the stringers may take more timethan desired.

Therefore, the illustrative embodiments recognize and take into accountthat it may be desirable to employ a system that allows for eachstringer to be compacted individually. Thus, the illustrativeembodiments recognize and take into account that with this type ofsystem, each stringer may be compacted immediately after installationwithout waiting for the installation of other stringers. As a result,each stringer is compacting and moving forward in the process whileother stringers are being installed. Further, the illustrativeembodiments recognize and take into account that it would be desirableto have a compacting system that reduces the amount of time andcomplexity that is currently needed with currently used vacuum bags.

Thus, the illustrative embodiments provide a method and apparatus forprocessing a stringer. In one illustrative embodiment, an apparatusincludes a compacting structure and a compactor vacuum system. Thecompacting structure has a shape configured to contact an internal wallof layers of uncured composite material for a composite stringer. Thevacuum system is associated with the compacting structure. The vacuumsystem is configured to cause the compacting structure to apply pressureto the layers of uncured composite material when a vacuum is applied tothe vacuum system.

Additionally, a carrier vacuum system also may be present that isassociated with a compacting structure. The carrier vacuum system isconfigured to hold the layers of uncured composite material against thecompacting structure when a carrier vacuum is applied to the carriervacuum system. This carrier vacuum system provides a mechanism foraiding in the transportation, adherence, and compaction of the layers ofuncured composite material into stringer channels in the tool.

With reference now to the figures, and in particular, with reference toFIG. 1, an illustration of a composite manufacturing environment isdepicted in accordance with an illustrative embodiment. In this depictedexample, composite manufacturing environment 100 is used to manufacturefuselage sections. As depicted, mold 102 may be inner-mold line (IML)tool 104. In other words, layers of uncured composite material may belaid up on outer surface 106 of mold 102.

In these illustrative examples, openings 108 are present on outersurface 106 of mold 102. Openings 108 are openings in which layers ofuncured composite material for stringers may be placed on mold 102.

In these illustrative examples, mold 102 may be a mold used forcompacting stringer preforms. In these illustrative examples, a stringerpreform is comprised of layers of uncured composite material for acomposite stringer. Each of the stringer preforms is placed in one ofopenings 108 for processing.

In other words, mold 102 is not the mold on which layers of uncuredcomposite material are laid up to form walls for the fuselage. In thisimplementation, after the stringer preforms are compacted, the stringerpreforms are removed and placed on another tool on which layers ofuncured composite material may be laid up to form the walls of thefuselage. In other illustrative examples, IML tool 104 may be a mold onwhich layers of uncured composite material are also laid up for thewalls of the fuselage section.

In these illustrative examples, stringer processing system 110 may beused to place and to compact layers of uncured composite material forcomposite stringers. In this illustrative example, stringer processingsystem 110 comprises stringer processing devices 112. In particular,stringer processing devices 112 include stringer processing device 114,stringer processing device 116, stringer processing device 118, andstringer processing device 120. Stringer processing device 114 islocated in channel 122 with stringer preform 124. Stringer processingdevice 116 is located in channel 126 with stringer preform 128. Stringerprocessing device 118 is located in channel 130 with stringer preform132. Stringer processing device 120 is located in channel 134 withstringer preform 136.

In these illustrative examples, stringer processing devices 112 are usedin place of a traditional vacuum bag. As a result, each time a stringerprocessing device is placed into a channel, the compacting of thestringer preform may begin at that time without waiting for theinstallation of other stringer preforms into other openings. Forexample, when stringer preform 124 is placed in channel 122 withstringer processing device 114, stringer processing device 114 may beginto compact stringer preform 124. Thereafter, when stringer preform 128is placed into channel 126 with stringer processing device 116, stringerprocessing device 116 may begin compacting stringer preform 128. In asimilar fashion, when stringer preform 132 is placed into channel 130with stringer processing device 118, the compacting of stringer preform132 may begin at that time without waiting for stringer preform 136 tobe placed in channel 134.

In this manner, the compacting of stringers may be performedindividually rather than in larger groups as currently performed. Inthis manner, a reduced amount of time may be present prior to placingother stringers onto mold 102. Further, with the use of stringerprocessing system 110, stringer preforms may be placed into openings 108in almost any orientation. As a result, less rotation or movement of IMLtool 104 may be needed to install and compact stringers into openings108.

The illustration of composite manufacturing environment 100 is not meantto imply limitations to the manner in which other compositemanufacturing environments may be implemented. In this illustrativeexample, other numbers of stringer processing devices may already beinstalled onto mold 102 other than the ones depicted.

Turning now to FIG. 2, an illustration of a block diagram of a compositemanufacturing environment is depicted in accordance with an illustrativeembodiment. As depicted, composite manufacturing environment 100 is anexample of one implementation for composite manufacturing environment200 in FIG. 2.

In this illustrative example, composite manufacturing environment 200may be used to process composite stringers 202. In these illustrativeexamples, stringer preforms 203 for composite stringers 202 may beplaced onto tool 204 for processing. In this illustrative example, tool204 takes the form of mold 206. Mold 206 has openings 208 in whichcomposite stringers 202 may be processed.

Mold 206 may be configured only for processing stringer preforms 203 forcomposite stringers 202. In other words, after stringer preforms 203 areprocessed, stringer preforms 203 may be moved to a second mold in whichadditional layers of uncured composite material may be laid up onstringer preforms 203 to form a structure such as a fuselage section.That second mold with the additional layers of uncured compositematerial and stringer preforms may then be cured to form the fuselagesection with the composite stringers. In other illustrative examples,mold 206 may be the mold on which the additional layers of uncuredcomposite material are laid up for the fuselage section and cured. Instill other illustrative examples, all of the layers of uncuredcomposite material to form composite stringers 202 may be laid up atonce.

In these illustrative examples, stringer preforms 203 for compositestringers 202 are placed into openings 208 on tool 204. Stringerpreforms 203 may be compacted on mold 206 using stringer processingsystem 110 from FIG. 1. In these illustrative examples, compactinginvolves applying pressure 212 onto stringer preforms 203. Pressure 212is a force applied to stringer preforms 203 in these illustrativeexamples. Pressure 212 is applied such that inconsistencies in compositestringers 202 manufactured from stringer preforms 203 may be reduced.

Stringer processing system 214 is comprised of stringer processingdevices 216. Each of stringer processing devices 216 is associated witha stringer preform in stringer preforms 203. Stringer processing devices216 in stringer processing system 214 are configured to apply pressure212 to stringer preforms 203.

Pressure 212 is applied individually to stringer preforms 203 bystringer processing devices 216. In other words, each of stringerprocessing devices 216 may apply pressure 212 to a stringer preform instringer preforms 203.

As depicted, pressure 212 is applied to stringer preforms 203 whenvacuum source 218 applies vacuum 220 to stringer processing devices 216.Vacuum source 218 may apply vacuum 220 independently to stringerprocessing devices 216. In other words, vacuum 220 may be applied to onestringer processing device in stringer processing devices 216 whilevacuum 220 is not applied to another stringer processing device instringer processing devices 216.

Vacuum source 218 may be comprised of a number of vacuum systems 222. Asused herein, a “number of” when used with reference to items means oneor more items. For example, a number of vacuum systems 222 is one ormore vacuum systems 222. In other words, vacuum source 218 may have morethan one vacuum system configured to apply vacuum 220 to stringerprocessing devices 216.

Turning now to FIG. 3, an illustration of a block diagram of a stringerprocessing device for processing a stringer is depicted in accordancewith an illustrative embodiment. In this illustrative example, stringerprocessing device 300 may be used to process stringer preform 302.

As depicted, stringer processing device 300 is an example of a stringerprocessing device in stringer processing devices 216 in FIG. 2. Stringerpreform 302 is an example of a stringer preform in stringer preforms 203in FIG. 2.

In this illustrative example, stringer processing device 300 comprisescompacting structure 304, compactor vacuum system 306, and carriervacuum system 308. Stringer preform 302 is comprised of layers ofuncured composite material 310 for composite stringer 312. Compositestringer 312 is an example of a composite stringer in compositestringers 202 in FIG. 2.

In this illustrative example, compacting structure 304 has shape 314.Shape 314 of compacting structure 304 is configured to contact internalwall 316 of layers of uncured composite material 310 for compositestringer 312. Internal wall 316 is a wall in channel 328 in compositestringer 312. In other words, shape 314 of compacting structure 304corresponds to channel 328 in an interior of composite stringer 312.

Compacting structure 304 may be comprised of a number of differentmaterials. For example, compacting structure 304 may be comprised of anumber of materials selected from at least one of a plastic, graphite,aluminum, a polycarbonate, wood, a composite material, a thermoplasticmaterial, and some other suitable materials. In these illustrativeexamples, the material may be a material selected that allows for avacuum to be drawn through, around, or both through and aroundcompacting structure 304.

The selection of the material for compacting structure 304 also may bebased on the ability of the material to provide a level of stiffnessthat does not deform in an undesirable manner when a vacuum, such ascompactor vacuum 320 and carrier vacuum 322 are applied. The materialfor compacting structure 304 also may be selected to provide compliancysuch that pressure 318 may be applied to all areas of stringer preform302 contacted by compacting structure 304.

As used herein, the phrase “at least one of”, when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of each item in the list may be needed. Forexample, “at least one of item A, item B, and item C” may include,without limitation, item A or item A and item B. This example also mayinclude item A, item B, and item C or item B and item C.

Compactor vacuum system 306 is associated with compacting structure 304.When one component is “associated” with another component, theassociation is a physical association in the depicted examples. Forexample, a first component, compacting structure 304, may be consideredto be associated with a second component, compactor vacuum system 306,by being secured to the second component, bonded to the secondcomponent, mounted to the second component, welded to the secondcomponent, fastened to the second component, and/or connected to thesecond component in some other suitable manner. The first component alsomay be connected to the second component using a third component. Thefirst component may also be considered to be associated with the secondcomponent by being formed as part of and/or an extension of the secondcomponent.

In these illustrative examples, vacuum source 218 in FIG. 2 may applyvacuum 220 to stringer processing device 300. Vacuum source 218 isconfigured to independently apply vacuum 220 to compactor vacuum system306 and carrier vacuum system 308. In particular, vacuum 220 may includecompactor vacuum 320 and carrier vacuum 322.

Compactor vacuum system 306 is configured to cause compacting structure304 to apply pressure 318 to layers of uncured composite material 310when compactor vacuum 320 is applied to compactor vacuum system 306. Asdepicted, pressure 318 may be applied to layers of uncured compositematerial 310 when layers of uncured composite material 310 in stringerpreform 302 for composite stringer 312 are placed into channel 324 oftool 204.

In other words, carrier vacuum system 308 may be used to hold layers ofuncured composite material 310 in the shape of stringer perform 302during transport and installation of layers of uncured compositematerial 310. After placing compacting structure 304 with layers ofuncured composite material 310 into tool 204, carrier vacuum 322 may bereleased from carrier vacuum system 308. When carrier vacuum system 308is turned off, compactor vacuum system 306 may be turned on in theseillustrative examples.

In the illustrative examples, carrier vacuum system 308 may be turnedoff prior to compactor vacuum system 306 being turned on. Further,carrier vacuum system 308 may be turned off after compactor vacuumsystem 306 is turned on. In other illustrative examples, carrier vacuumsystem 308 may be turned off at substantially the same time thatcompactor vacuum system 306 is turned on.

In this illustrative example, layers of uncured composite material 310are located between compacting structure 304 and walls 326 in channel324 of tool 204. Pressure 318 is applied to layers of uncured compositematerial 310 by the movement of compacting structure 304 towards walls326 of tool 204.

In this illustrative example, compactor vacuum system 306 may comprisefirst port 330, enclosure structure 332, and seal 334. First port 330provides a connection to enclosure structure 332 and to a vacuum sourcethat applies compactor vacuum 320.

Enclosure structure 332 is configured to define first space 336 throughwhich compactor vacuum 320 may be applied. Enclosure structure 332 isassociated with compacting structure 304 such that compactor vacuum 320causes pressure 318.

Enclosure structure 332 may be comprised of a number of differentmaterials. For example, enclosure structure 332 may be comprised of anumber of materials selected from at least one of plastic, a closed-cellfoam, polyurethane, silicone, vinyl, and other suitable materials.

Seal 334 is associated with enclosure structure 332. In theseillustrative examples, seal 334 is associated with enclosure structure332 such that a vacuum may be applied within first space 336 whenenclosure structure 332 is placed on layers of uncured compositematerial 310 in stringer preform 302.

Seal 334 may be comprised of a number of different materials. Further,seal 334 may be comprised of any material that allows for first vacuum320 to be applied to compactor vacuum system 306. For example, seal 334may be comprised of a material selected from at least one of a syntheticrubber, a thermoplastic elastomer, polyurethane, butyl rubber, and othersuitable materials.

Seal 334 does not need to be an airtight seal in all cases. The sealprovided by seal 334 may be sufficient such that pressure 318 may begenerated by compacting structure 304 when compactor vacuum 320 isapplied to compactor vacuum system 306. Further, seal 334 may beselected from a material that does not cause contamination to layers ofuncured composite material 310 in stringer preform 302 that come intocontact with seal 334.

In this illustrative example, carrier vacuum system 308 comprises secondport 338 and channel 340. Channel 340 extends through compactingstructure 304 in this illustrative example. Second port 338 provides aconnection between channel 340 and a vacuum source that applies carriervacuum 322. Openings 342 are present and are also part of carrier vacuumsystem 308 in compacting structure 304. Openings 342 providecommunication between channel 340 and the exterior of compactingstructure 304.

When carrier vacuum 322 is applied and compacting structure 304 isplaced against layers of uncured composite material 310, layers ofuncured composite material 310 may be held against tool 204.

As depicted, carrier vacuum system 308 is associated with tool 204.Carrier vacuum system 308 is configured to hold layers of uncuredcomposite material 310 against tool 204 when carrier vacuum 322 isapplied to carrier vacuum system 308.

In these illustrative examples, carrier vacuum system 308 with carriervacuum 322 may press layers of uncured composite material 310 againsttool 204 to lay up the layers of uncured composite material on tool 204.As a result, layers of uncured composite material 310 may be pressedagainst channel 324 and walls 326 in tool 204.

In this manner, stringer processing device 300 may also move stringerpreform 302 to the desired location. Additionally, stringer processingdevice 300 may be used to move stringer preform 302 after beingcompacted to another location such as a mold used for curing dependingon the particular implementation.

The illustration of composite manufacturing environment 200 and thedifferent components in FIGS. 2 and 3 are not meant to imply physical orarchitectural limitations to the manner in which an illustrativeembodiment may be implemented. Other components in addition to or inplace of the ones illustrated may be used. Some components may beunnecessary. Also, the blocks are presented to illustrate somefunctional components. One or more of these blocks may be combined,divided, or combined and divided into different blocks when implementedin an illustrative embodiment.

For example, although both compactor vacuum system 306 and carriervacuum system 308 are present in stringer processing device 300 in theillustrative example, both vacuum systems may not be needed. Forexample, stringer processing device 300 may only include compactorvacuum system 306.

As another example, carrier vacuum system 308 is shown as a separateblock from compacting structure 304 in FIG. 3. In other illustrativeexamples, carrier vacuum system 308 may include compacting structure 304even though they are shown as different components.

In still another illustrative example, enclosed structure 332 may notalways define first space 336. In some cases, enclosed structure 332 mayinclude openings, holes, or other paths through which a vacuum may bedrawn to cause compacting structure 304 to apply pressure 318 to layersof uncured composite material 310 without needing first space 336.

In these illustrative examples, enclosed structure 332 may takedifferent forms. For example, without limitation, enclosure structure332 may be enclosed structure 332 may be selected from one of a vacuumbag, a flexible structure with a seal, and other suitable structures.

In the illustrative examples, only a single port is illustrated for eachof the vacuum systems. In other implementations, one or more additionalports may be present in addition to first port 330, second port 338, orboth.

In yet another illustrative example, stringer processing device 300 mayhave a shape that corresponds to the shape of tool 204. For example, iftool 204 has a curved shape, stringer processing device 300 may alsohave a shape that is configured to conform to the curve of tool 204.

In still other illustrative examples, stringer processing device 300 maybe flexible in shape. The materials may be selected such that thedifferent components in stringer processing device 300 may bend to havea shape that corresponds to the shape of tool 204. In other words, ifchannel 324 has a curve or bend, stringer processing device 300 may bendto conform to the curve or bend in channel 324.

Further, in some illustrative examples, the design of the components instringer processing device 300 may allow for bending of stringerprocessing device 300 to correspond to a shape of tool 204. This bendingmay occur about an axis of stringer processing device 300. For example,bending of the components in stringer processing device 300 may occurabout the longitudinal axis. In other illustrative examples, a twistingmay also occur about an axis of stringer processing device 300.

Turning now to FIG. 4, an illustration of a stringer processing deviceis depicted in accordance with an illustrative embodiment. In thisillustrative example, a view of stringer processing device 400 is shown.In this example, FIG. 4 illustrates a view of stringer processing device400 from side 401 of stringer processing device 400. Stringer processingdevice 400 is an example of one implementation of stringer processingdevice 300 shown in block form in FIG. 3 and is an example of a stringerprocessing device that may be used in stringer processing devices 112 inFIG. 1.

Side 401 may be considered a top side of stringer processing device 400.In other words, side 401 may face away from the surface of the mold.

As depicted, stringer processing device 400 includes compactingstructure 402, compactor vacuum system 404, and carrier vacuum system406. These components in stringer processing device 400 may be used toprocess a stringer preform for a composite stringer. Compactingstructure 402 is configured to contact layers of uncured compositematerial in the stringer perform for the composite stringer.

Compactor vacuum system 404 is comprised of enclosure structure 408,seal 410, and first port 412. Enclosure structure 408 is configured todefine a space. This space is an enclosed space when seal 410 is placedagainst layers of uncured composite material for a stringer preform.

In this illustrative example, enclosure structure 408 may be comprisedof a sheet of flexible material. This material may be the same materialused for vacuum bags. As depicted, enclosure structure 408 issubstantially transparent in this illustrative example.

Seal 410 is located at the periphery 411 of enclosure structure 408.Seal 410 is configured to create a seal such that a vacuum may beapplied to the enclosed space. In this illustrative example, enclosurestructure 408 covers side 420 of compacting structure 402.

As depicted, compactor vacuum system 404 is configured to causecompacting structure 402 to apply pressure to the layers of uncuredcomposite material when placed against IML tool. This pressure may beapplied when a vacuum is applied to compactor vacuum system 404 throughfirst port 412.

In this view, second port 416 is seen. Second port 416 is a port forcarrier vacuum system 406.

Turning now to FIG. 5, an illustration of an isometric view of astringer processing device is depicted in accordance with anillustrative embodiment. In this illustrative view, side 500 of stringerprocessing device 400 is shown.

In this view, additional components in carrier vacuum system 406 areshown. As depicted, channel 501 is shown in phantom extending throughthe interior of compacting structure 402. Openings 502 are shown on side503 of compacting structure 402. Openings 502 are in communication withchannel 501 within the interior of compacting structure 402. Opening504, opening 506, and opening 508 are examples of some openings inopenings 502 in compacting structure 402.

In this view, flange 510 and flange 512 are shown on compactingstructure 402. Flange 510 and flange 512 may aid in applying pressureagainst a stringer preform.

With reference now to FIG. 6, an illustration of a stringer processingdevice with a stringer preform positioned relative to a tool is depictedin accordance with an illustrative embodiment. First port 412 incompactor vacuum system 404 is connected to a vacuum source by hose 600.As depicted, second port 416 in carrier vacuum system 406 is connectedto a vacuum source by hose 602.

As illustrated, layers of uncured composite material 604 for stringerpreform 606 are held by stringer processing device 400. In particular,layers of uncured composite material 604 for stringer preform 606 areheld against surface 608 of compacting structure 402 with a vacuumapplied to carrier vacuum system 406 through second port 416, channel501, and through openings 502 in FIG. 5.

As depicted, stringer processing device 400 with layers of uncuredcomposite material 604 for stringer preform 606 are positioned relativeto channel 610 of tool 612.

Turning now to FIG. 7, an illustration of a cross-sectional view of astringer processing device holding a stringer preform is depicted inaccordance with an illustrative embodiment. In this example, across-sectional view of stringer processing device 400 with stringerpreform 606 over tool 612 taken along lines 7-7 in FIG. 4 is shown. Inthis view of stringer processing device 400, channel 700 is seen withinwall 702 of compacting structure 402.

As depicted, stringer processing device 400 with stringer preform 606may be moved toward tool 612 in the direction of arrow 704. The movementin the direction of arrow 704 may be such that stringer preform 606 maybe sandwiched between stringer processing device 400 and tool 612. Inother words, compacting structure 402 moves towards surface 608 of tool612 with layers of uncured composite material 604 in stringer preform606 located between compacting structure 402 and tool 612 such thatcompacting structure 402 applies pressure to layers of uncured compositematerial 604.

In this illustrative example, carrier vacuum system 406 applies a vacuumto layers of uncured composite material 604 and stringer preform 606.This vacuum is applied to hold stringer preform 606 during transport andmovement relative to surface 608 of tool 612.

Turning now to FIG. 8, another cross-sectional view of a stringerprocessing device with a stringer preform in a channel of a tool isdepicted in accordance with an illustrative embodiment. In this view,stringer processing device 400 with stringer preform 606 has been movedinto channel 610. In this position, a vacuum may be applied to compactorvacuum system 404 such that compacting structure 402 applies pressureagainst layers of uncured composite material 604 in stringer preform 606in the direction of arrow 704. Layers of uncured composite material 604are located between compacting structure 402 and surface 608 of channel610.

Additionally, when carrier vacuum system 406 may be turned off, carriervacuum system 406 does not apply a vacuum to layers of uncured compositematerial 604 in stringer preform 606. This vacuum is no longer needed tomove stringer preform 606.

In this manner, layers of uncured composite material 604 may becompacted. This compacting may reduce undesired features such as voids,air pockets, wrinkles, or other undesired features in layers of uncuredcomposite material 604. This compacting may be performed for a period oftime. This period of time may be, for example, ten minutes, thirtyminutes, one hour, or some other suitable amount of time.

With reference now to FIG. 9, an illustration of a stringer processingdevice is depicted in accordance with an illustrative embodiment.Stringer processing device 900 is an example of another physicalimplementation for stringer processing device 300 shown in block form inFIG. 3.

As depicted, stringer processing device 900 includes compactingstructure 902, compactor vacuum system 904, and carrier vacuum system906. In this illustrative example, compactor vacuum system 904 iscomprised of first port 908, second port 910, enclosure structure 912,and seal 914. As can be seen, seal 914 is located around periphery 913of enclosure structure 912. In particular, seal 914 is not on periphery913 in this illustrative example.

In this example, both first port 908 and second port 910 may beconnected to a vacuum source in this particular example. Enclosurestructure 912 defines space 916 in which a vacuum may be drawn whenenclosure structure 912 with seal 914 are placed against a stringerpreform.

In this illustrative example, carrier vacuum system 906 comprises thirdport 918, channel 919, and openings 920. In this example, channel 919 isshown in phantom as extending through the interior of compactingstructure 902. As depicted, openings 920 are in communication withchannel 919 within compacting structure 902.

With reference now to FIG. 10, an illustration of a cross section of astringer processing device is depicted in accordance with anillustrative embodiment. In this illustrative example, a cross-sectionalview of stringer processing device 900 taken along lines 10-10 in FIG. 9is shown. In this view, compactor vacuum system 904 for stringerprocessing device 900 is shown. Carrier vacuum system 906 for stringerprocessing device 900 is not seen in this view.

In this illustrative example, enclosure structure 912 for compactorvacuum system 904 is comprised of openings 1000 extending throughplastic structure 1002. Openings 1004 are present on side 1006 ofplastic structure 1002. Openings 1004 provide communication betweenopenings 1000 and space 916. In this illustrative example, plasticstructure 1002 may be comprised of a plastic material that is flexible.

Turning now to FIG. 11, another illustration of a cross section of astringer processing device is depicted in accordance with anillustrative embodiment. In this illustrative example, stringerprocessing device 1100 is shown in a cross-sectional view. Stringerprocessing device 1100 is an example of a physical implementation forstringer processing device 300 shown in block form in FIG. 3.

As depicted, compacting structure 1102 is shown with compactor vacuumsystem 1104. Channel 1105 for carrier vacuum system 1107 is seen withinthe interior of compacting structure 1102 in this view. Other componentsfor carrier vacuum system 1107 are not seen in this view.

As depicted, compactor vacuum system 1104 comprises enclosure structure1106 and seal 1108. Enclosure structure 1106 defines space 1110.

In this illustrative example, enclosure structure 1106 is comprised offoam 1112. In particular, foam 1112 is a closed-cell foam in theseillustrative examples.

Turning now to FIG. 12, another illustration of a cross section of astringer processing device is depicted in accordance with anillustrative embodiment. In this illustrative example, stringerprocessing device 1200 is shown in a cross-sectional view. Stringerprocessing device 1200 is an example of a physical implementation forstringer processing device 300 shown in block form in FIG. 3.

As depicted, compacting structure 1202 is shown with compactor vacuumsystem 1204. Channel 1205 for carrier vacuum system 1207 is seen withinthe interior of compacting structure 1202 in this view. Other componentsfor carrier vacuum system 1207 are not seen in this view. As depicted,compactor vacuum system 1204 comprises enclosure structure 1206, seal1208, and port 1209.

As depicted, enclosure structure 1206 comprises first structure 1210 andsecond structure 1212. These two structures are associated with eachother.

In this illustrative example, first structure 1210 is comprised of anon-porous material while second structure 1212 is comprised of a porousmaterial. For example, first structure 1210 may be comprised of amaterial such as plastic, polycarbonate, or some other suitablematerial. Second structure 1212 may be comprised of polyurethane, foam,and other suitable materials that may be porous.

As depicted, openings 1214 extend through first structure 1210. Openings1214 are in communication with port 1209 such that a vacuum applied toport 1209 may extend through openings 1214. The vacuum may also extendthrough second structure 1212 when second structure 1212 is comprised ofa porous material.

With reference now to FIG. 13, yet another illustration of a crosssection of a stringer processing device is depicted in accordance withan illustrative embodiment. In this illustrative example, stringerprocessing device 1300 is shown in a cross-sectional view. Stringerprocessing device 1300 is an example of a physical implementation forstringer processing device 300 shown in block form in FIG. 3.

As depicted, compacting structure 1302 is shown with compactor vacuumsystem 1304. Channel 1305 for carrier vacuum system 1307 is seen withinthe interior of compacting structure 1302 in this view. Other componentsfor carrier vacuum system 1307 are not seen in this view. As depicted,compactor vacuum system 1304 comprises enclosure structure 1306, seal1308, and port 1309.

As depicted, enclosure structure 1306 comprises first structure 1310 andsecond structure 1312. Second structure 1312 is located within firststructure 1310 in this depicted example.

First structure 1310 is a solid non-porous material. Second structure1312 is a honeycomb structure. In particular, the honeycomb structuremay be a vented honeycomb structure such that different cells in thehoneycomb structure have openings to other cells in the honeycombstructure.

For example, first structure 1310 may be comprised of a material such asplastic, polycarbonate, or some other suitable material. Secondstructure 1312 may be comprised of paper, polyurethane, plastic, or anyother suitable materials that may be used to form a honeycomb structure.In these illustrative examples, port 1309 is in communication withsecond structure 1312.

As depicted, first structure 1310 may be comprised of first facesheet1314, second facesheet 1316, and edge fill 1318. Edge fill 1318 ispresent around periphery 1320 of second structure 1312.

Openings 1322 are present in first facesheet 1314 in this illustrativeexample. In this manner, when a vacuum is applied to compactor vacuumsystem 1304, compacting structure 1302 may apply pressure to layers ofuncured composite material.

With reference now to FIG. 14, another illustration of a stringerprocessing device 1400 is depicted in accordance with an illustrativeembodiment. Stringer processing device 1400 is an example of anotherphysical implementation for stringer processing device 300 shown inblock form in FIG. 3.

In this illustrative example, stringer processing device 1400 has ashape that corresponds to the shape of tool 204 in FIG. 2. In thismanner, shape of stringer processing device 1400 may be fixed or theshape of stringer processing device 1400 may be flexible to have a shapeas depicted in this example.

The materials for stringer processing device 1400 may be selected suchthat the different components in stringer processing device 1400 maybend such that the shape corresponds to the shape of tool 204.

As depicted, stringer processing device 1400 includes compactingstructure 1402, compactor vacuum system 1404, and carrier vacuum system1406. As depicted, the compacting structure 1402, compactor vacuumsystem 1404, and carrier vacuum system 1406 are flexible such that theshape of compacting structure 1402, the shape of compactor vacuum system1404, and the shape of carrier vacuum system 1406 are configured to bendto correspond to a shape of a tool.

In this illustrative example, compactor vacuum system 1404 is comprisedof first port 1408, second port 1410, enclosure structure 1412, and seal1414. As can be seen, seal 1414 is located around periphery 1413 ofenclosure structure 1412. In particular, seal 1414 is not on periphery1413 in this illustrative example.

In this example, both first port 1408 and second port 1410 may beconnected to a vacuum source in this particular example. Enclosurestructure 1412 defines space 1416 in which a vacuum may be drawn whenenclosure structure 1412 with seal 1414 are placed against a stringerpreform.

In this illustrative example, carrier vacuum system 1406 comprises thirdport 1418, channel 1419, and openings 1420. In this example, channel1419 is shown in phantom as extending through the interior of compactingstructure 1402. As depicted, openings 1420 are in communication withchannel 1419 within compacting structure 1402.

The illustration of stringer processing devices in FIGS. 4-14 are onlyprovided as examples of some physical implementations for stringerprocessing device 300 shown in block form in FIG. 3. These differentillustrations are not meant to limit the manner in which stringerprocessing device may be implemented. For example, the seals may beintegrated as part of the enclosure structure rather than as separatestructures connected to the enclosure structure as shown in the depictedexamples. Further, compacting structure 1202 in FIG. 12 may have adifferent shape rather than the “hat” shape shown in these examples. Forexample, the graphite compactors may have a square shape, a rounded hatshape, an omega hat shape, or other shapes depending on the particularstringer being processed.

The different components shown in FIGS. 1 and 4-14 may be combined withcomponents in FIGS. 2 and 3, used with components in FIGS. 2 and 3, or acombination of the two, Additionally, some of the components in FIGS. 1and 4-14 may be illustrative examples of ho components shown in blockform in FIGS. 2 and 3 can be implemented as physical structures.

Turning now to FIG. 15, an illustration of a flowchart of a process forprocessing a composite stringer is depicted in accordance with anillustrative embodiment. The process illustrated in FIG. 15 may beimplemented in composite manufacturing environment 100 in FIG. 1 andcomposite manufacturing environment 200 in FIG. 2.

The process begins by placing layers of uncured composite material for acomposite stringer onto a mold (operation 1500). The process thenapplies a vacuum to a vacuum system associated with a compactingstructure such that the layers of uncured composite material of thecomposite stringer are compacted against the mold (operation 1502) withthe process terminating thereafter.

With reference now to FIG. 16, an illustration of a flowchart of aprocess for processing composite stringers is depicted in accordancewith an illustrative embodiment. The process illustrated in FIG. 16 isan example of a process that may be used to compact layers of uncuredcomposite material for a stringer preform for a composite stringer. Thisprocess may be applied to multiple stringer preforms in theseillustrative examples.

The process begins by identifying a group of stringer processing deviceswith stringer preforms (operation 1600). As used herein, a “group of”when used with reference to items means one or more items. For example,a group of stringer processing devices is one or more stringerprocessing devices.

In these illustrative examples, each of the other stringer processingdevices has a compacting structure, a compactor vacuum system, and acarrier vacuum system. The process selects one of the stringerprocessing devices for processing (operation 1602).

The process then applies a vacuum to a carrier vacuum system (operation1604). The application of the vacuum to the carrier vacuum system causesthe carrier vacuum system to apply a carrier vacuum to the layers ofuncured composite material. Further, the application of the carriervacuum by the carrier vacuum system is configured to hold the layers ofuncured composite material for the stringer preform against thecompacting structure in the stringer processing device.

The stringer processing device with the stringer preform is moved to atool (operation 1606). The stringer processing device with the stringerpreform is placed into a channel in the tool that is empty (operation1608). After the stringer processing device with the stringer preform isplaced into the channel, a vacuum is applied to a compactor vacuumsystem (operation 1610). This vacuum applied to the compactor vacuumsystem causes the compacting structure to apply pressure to the layersof uncured composite material for the stringer preform in the mold in amanner that compacts the layers of uncured composite material. Theprocess then releases the vacuum applied to the carrier vacuum system(operation f1611).

A determination is made as to whether an additional stringer processingdevice with a stringer preform is present in the group (operation 1612).If an additional stringer processing device is present, the processdetermines whether an empty channel is present in the tool (operation1614). If an empty channel is present, the process returns to operation1602. Otherwise, the process waits for a period of time (operation1616). After the period of time passes, the process returns to operation1614.

With reference again to operation 1612, if an additional stringerprocessing device with a stringer preform is not present in the group,the process terminates.

In this manner, stringer preforms may be processed as they are placedinto a channel on a tool rather than waiting for multiple stringerpreforms to be placed into the openings and placing compactingstructures onto stringer preforms on the tool and a vacuum bag overstringer preforms and then drawing a vacuum to compact the stringerpreforms. In this manner, as individual stringer preforms are compacted,those stringer preforms may be moved to another tool where compactmaterials may be laid up for a composite structure such as a fuselagesection.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatus and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent a module, segment, function, and/or a portion ofan operation or step. For example, one or more of the blocks may beimplemented as program code, in hardware, or a combination of theprogram code and hardware. When implemented in hardware, the hardwaremay, for example, take the form of integrated circuits that aremanufactured or configured to perform one or more operations in theflowcharts or block diagrams.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

For example, operation 1610 and operation 1611 in the flowchart in FIG.16 may be performed in a different order than shown. In other words, thevacuum applied to the carrier vacuum system may be released prior toapplying the vacuum to the compact vacuum system after the stringerprocessing device with the stringer preform has been placed into thechannel. In other illustrative examples, these two operations may beperformed at substantially the same time.

Illustrative embodiments of the disclosure may be described in thecontext of aircraft manufacturing and service method 1700 as shown inFIG. 17 and aircraft 1800 as shown in FIG. 18. Turning first to FIG. 17,an illustration of an aircraft manufacturing and service method isdepicted in accordance with an illustrative embodiment. Duringpre-production, aircraft manufacturing and service method 1700 mayinclude specification and design 1702 of aircraft 1800 in FIG. 18 andmaterial procurement 1704.

During production, component and subassembly manufacturing 1706 andsystem integration 1708 of aircraft 1800 in FIG. 18 takes place.Thereafter, aircraft 1800 in FIG. 18 may go through certification anddelivery 1710 in order to be placed in service 1712. While in service1712 by a customer, aircraft 1800 in FIG. 18 is scheduled for routinemaintenance and service 1714, which may include modification,reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 1700may be performed or carried out by a system integrator, a third party,and/or an operator. In these examples, the operator may be a customer.For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party may include, withoutlimitation, any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, a leasing company, a military entity, aservice organization, and so on.

With reference now to FIG. 18, an illustration of an aircraft isdepicted in which an illustrative embodiment may be implemented. In thisexample, aircraft 1800 is produced by aircraft manufacturing and servicemethod 1700 in FIG. 17 and may include airframe 1802 with plurality ofsystems 1804 and interior 1806. Examples of systems 1804 include one ormore of propulsion system 1808, electrical system 1810, hydraulic system1812, and environmental system 1814. Any number of other systems may beincluded. Although an aerospace example is shown, different illustrativeembodiments may be applied to other industries, such as the automotiveindustry.

Apparatuses and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 1700 inFIG. 17. For example, stringer processing system 214 may be used duringcomponent and subassembly manufacturing 1706 to process stringerpreforms. In particular, stringer processing system 214 may be used tocompact stringer preforms individually. In this manner, stringerpreforms may be available more quickly for use in forming stringers andfor integration into other composite structures such as a fuselagesection, a wing, a horizontal stabilizer, and other suitable compositestructures.

Further, stringer processing system 214 also may be used to processstringers during maintenance and service 1714. For example, stringersmay be processed for new composite structures that may be fabricatedduring maintenance, refurbishments, upgrades, and other operations. Theuse of a number of the different illustrative embodiments maysubstantially expedite the assembly of and/or reduce the cost ofaircraft 1800.

Thus, the illustrative embodiments provide a method and apparatus forprocessing a composite stringer. In particular, one or more illustrativeembodiments may be used to process layers of uncured composite materialin a stringer preform for a composite stringer. In one illustrativeexample, a stringer processing device may be used to compact thestringer. Further, the stringer processing device also may be used tomove the stringer preform to different locations.

With the use of a stringer processing system that includes stringerprocessing devices, the amount of time and effort needed to processcomposite stringers may be reduced. As a result, the amount of timeneeded to manufacture aircraft and structures for aircraft also may bereduced. In particular, the time and labor used to move and place vacuumbags over multiple stringers on a tool may be avoided. Instead, thestringer processing devices may be used to move and compact the layersof uncured composite material for the composite stringers.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherillustrative embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A method for processing a composite stringer, themethod comprising: placing layers of uncured composite material for acomposite stringer onto a tool; and applying a compactor vacuum to acompactor vacuum system associated with a compacting structure such thatthe layers of uncured composite material of the composite stringer arecompacted against the tool; wherein the compacting structure furthercomprises: a first surface having a shape of one side of the compositestringer; and a second surface, wherein the first surface and the secondsurface form an enclosure structure when the compacting structure isplaced against a mold; wherein the first surface further comprises afirst opening in the first surface; and wherein the second surfacefurther comprises a number of second openings in the second surface;further comprising: applying a compactor vacuum to the enclosurestructure by the compactor vacuum system associated with the firstopening of the compacting structure; applying a pressure to layers ofuncured composite material when the compactor vacuum system applies thecompactor vacuum to the enclosure structure; applying a carrier vacuumto a carrier vacuum system associated with the number of second openingsin the second surface; and holding the layers of uncured compositematerial against the compacting structure by the carrier vacuum whilethe compacting structure is positioned and placed against the mold. 2.The method of claim 1 further comprising: placing a number of additionallayers of uncured composite material for a number of additionalstringers on the tool; and applying the vacuum to a number of additionalvacuum systems associated with a number of additional compactingstructures such that the number of additional layers of uncuredcomposite material for a number of additional composite stringers iscompacted against the tool.
 3. The method of claim 2, wherein the stepof applying the vacuum to the number of additional vacuum systemsassociated with the number of additional compacting structures such thatthe number of additional layers of uncured composite material for thenumber of additional composite stringers is compacted against the toolis performed as the number of additional layers of uncured compositematerial for the number of additional composite stringers is placed ontothe tool.
 4. The method of claim 1, wherein a shape of the compactingstructure corresponds to a channel in an interior of the compositestringer.
 5. The method of claim 1 further comprising: applying acarrier vacuum to a carrier vacuum system associated with the compactingstructure such that the layers of uncured composite material for thecomposite stringer are held against the compacting structure; andplacing the layers of uncured composite material for the compositestringer on the tool.
 6. The method of claim 5, wherein the compactorvacuum system comprises a port configured to be connected to a vacuumsource and an enclosure structure configured to cause the compactingstructure to move the compacting structure towards a surface of the toolwith the layers of uncured composite material located between thecompacting structure and the tool such that the compacting structureapplies a pressure to the layers of uncured composite material, whereinthe enclosure structure is in communication with the port.
 7. The methodof claim 5, wherein the carrier vacuum system comprises a portconfigured to be connected to a vacuum source and a number of openingsextending through the compacting structure, wherein the port is incommunication with the number of openings.
 8. The method of claim 1,further comprising: applying pressure to the layers of uncured compositematerial by compacting structure when the compactor vacuum system isapplied such that the layers of uncured composite material arecompacted.
 9. The method of claim 8, further comprising: applying thepressure to the layers of uncured composite material compactingstructure when the compactor vacuum system is applied such that thelayers of uncured composite material are compacted when the layers ofuncured composite material are placed in the mold.
 10. The method ofclaim 1, wherein the shape of the second surface of the compactingstructure corresponds to a channel in an interior of the compositestringer.
 11. The method of claim 1, wherein the compactor vacuum systemcomprises a port configured to be connected to a vacuum source, themethod further comprising: pushing the compacting structure towards asurface of a mold with the layers of uncured composite material locatedbetween the compacting structure and the mold, wherein an enclosurestructure is configured to push the compacting structure such that thecompacting structure applies a pressure to the layers of uncuredcomposite material, wherein the enclosure structure is in communicationwith the port.
 12. The method of claim 11, wherein the enclosurestructure is selected from one of a vacuum bag, and a flexible structurewith a seal.
 13. The method of claim 1, further comprising: holding thelayers of uncured composite material against the compacting structureduring movement of the compacting structure when a carrier vacuum isapplied, wherein a carrier vacuum system is configured to hold thelayers of uncured composite material.
 14. The method of claim 1, whereinthe carrier vacuum system comprises: a port configured to be connectedto a vacuum source; and a channel extending through the compactingstructure, wherein the port is in communication with a number of secondopenings in the compacting structure that connect the channel to anexterior of the compacting structure, wherein the number of secondopenings is located on a portion of the compacting structure thatcontacts the layers of uncured composite material.
 15. The method ofclaim 1 further comprising: independently apply the compactor vacuum anda carrier vacuum by a vacuum source.
 16. The method of claim 1, whereinthe compacting structure, the compactor vacuum system, and the carriervacuum system are flexible, the method further comprising: bending atleast one of a shape of the compacting structure, a shape of thecompactor vacuum system, and a shape of the carrier vacuum system tocorrespond to a shape of a mold.
 17. The method of claim 1, wherein thecompacting structure is comprised of a number of materials selected fromat least one of a plastic, graphite, aluminum, a polycarbonate, wood,and a composite material.